The Connected Enterprise Energy Concerns

Transcription

1 The Connected Enterprise Energy Concerns

2 Table of Contents TABLE OF CONTENTS 1 THE CONNECTED ENTERPRISE ENERGY CONCERNS 3 ABOUT THIS SCRIPT 3 DELIVERY OPTIONS 4 USING THIS SCRIPT 5 BEFORE YOU BEGIN 6 DEMO THE CONNECTED ENTERPRISE ENERGY CONCERNS 7 CHAPTER 1 CORPORATE - KPIS 8 CHAPTER 2 ANALYSIS ACROSS SITES MOBILE 10 CHAPTER 3 ANALYSIS ACROSS ALL SITES - TREND 13 CHAPTER 4 EQUIPMENT PERFORMANCE - MOBILE 17 CHAPTER 5 EQUIPMENT PERFORMANCE DESKTOP 19 CHAPTER 6A HOW S THE LINE RUNNING? (VIEWPOINT) 22 CHAPTER 6B HOW S THE LINE RUNNING? (VIEWSE) 25 CHAPTER 7 DESCRIPTIVE ANALYTICS 29 SUMMARY 35 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 1 of 36

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4 The Connected Enterprise Energy Concerns About This Script This script provides the necessary steps and talking points needed to demonstrate Energy related subjects, using the MightyQ s Cookie Company s Connected Enterprise. This script shows how various employees of the fictional MightyQ s Cookie Company use their Connected Enterprise across multiple sites with respect to their Energy Concerns. Different employees including the Director of Operations, the Maintenance Manager, a Line Operator, and the Plant Manager access data specific to their roles. This presentation covers the following attributes, with an emphasis on: Key Performance Indicators (KPIs) Energy Analysis Equipment Performance Line Performance Descriptive Analytics This script provides an example you can follow with your customer. The purpose of the script is to provide you with the talking points, you are encouraged to embellish and augment the script to meet your style and your audience. Do not feel that you are bound to follow the script exactly. Be creative and make it yours. Note that there is much more content that you can leverage within the system. You are encouraged to become familiar with the other reports and analyses in order to better serve your customer. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 3 of 36

5 Delivery Options As the presenter of this demonstration, you have several options for delivering the demonstration, they are: Via a VMware Image o This is the most efficient way to deliver the demo as all of the tools are installed on the single image Via your PC using the CIient Tools and leveraging the Demo as a Service (DaaS) Site o Certain client tools would need to be installed and configured prior to use Windows KPI app on Windows 8.1 or 10 (downloaded from the Microsoft Store) VantagePoint Client Tools installed from the Portal Chrome would need to be installed on your PC o This has the benefit of showing a working system and allows you to go off script if needed o This also comes with risks associated with network speed that may affect performance. Via the PowerPoint Presentation o A set of PowerPoint slides are available that cover this demonstration o This is static and will not allow you to go off script. o This has the benefit of not requiring Internet access and therefore not being affected by performance issues o It has reduced impact for the customer as it is not live Via a Video o Each of the chapters has a supporting video that can be run from the DaaS o You can turn off the speakers to allow you to talk to the video as it runs Via a Remote Desktop Connection to a Client Image, this would be a Live Demonstration o This method allows you to remote into an image that already is configured with all of the client tools o This would require special access that you will need to request in advance 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 4 of 36

6 Using This Script First, familiarize yourself with this script before presenting to your customer. Each Chapter in this manual walks you through demonstrating the different scenarios our customers are facing and explains important features and capabilities. This manual provides the following information for each display (when applicable): 1. Page Description - A high-level description of the page / content being demonstrated. It will often identify the product being used The story board provides the story behind the demonstration. Its purpose is to help put the demonstration into a real-world context. Use it as is or add your own version. It is provided to give you some context to use when presenting to your customer; you do not need to memorize it word for word. 3. Value - Value statement to the Customer Actions you perform in order to demonstrate the capabilities and features identified. Every customer is motivated a little differently, so customize your delivery using your sales skills. You have exciting products that can make your clients more productive, so keep that in mind as you find a path forward with your customer. Script Example: A high-level description of the page / content being demonstrated. It will often identify the product being used. Actions you perform in order to demonstrate the capabilities and features identified. Screen shot of the demonstration. Value statement to the Customer. The story board provides the story behind the demonstration. Its purpose is to help put the demonstration into a real-world context. Use it as is or add your own version. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 5 of 36

7 Before You Begin It is recommended that you become familiar with the MightyQ s Cookie Company prior to utilizing this demonstration. You can find training material on Noggin at: Should you choose to use the DaaS, you should run through the following checklist prior to the demonstration: Ensure that you can connect to the DaaS site ( Ensure that the speed of your network connection is adequate to run the demonstration to the customer s satisfaction Optionally, connect to the demonstration in advance to avoid the login page 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 6 of 36

8 Demo The Connected Enterprise Energy Concerns This demonstration is separated into the following Chapters: CHAPTER 1 CORPORATE - KPIS CHAPTER 2 ANALYSIS ACROSS SITES MOBILE CHAPTER 3 ANALYSIS ACROSS ALL SITES - TREND CHAPTER 4 EQUIPMENT PERFORMANCE - MOBILE CHAPTER 5 EQUIPMENT PERFORMANCE DESKTOP CHAPTER 6a HOW S THE LINE RUNNING? (ViewPoint) CHAPTER 6b HOW S THE LINE RUNNING? (ViewSE) CHAPTER 7 DESCRIPTIVE ANALYTICS You can demonstrate the entire script together or just select the individual chapters. It is recommended that you are familiar with the complete story in case you are asked to demonstrate the other chapters. For the rest of this document, it will be assumed that you are doing a live demonstration. If you are using the PowerPoint, you will simply need to advance the slides in order to remain in-sync with this document. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 7 of 36

9 Chapter 1 Corporate - KPIs 1. Page Description This is the FactoryTalk VantagePoint Windows KPI (Key Performance Indicator) application home page. It shows the current status of each defined KPI in the system. When the indicator shows green, it means targets are being met. KPIs indicating yellow or red may need attention. 1. Open the FactoryTalk VantagePoint KPI app and connect to the VantagePoint server. 2. The application loads the KPIs from the system. 3. Review the KPIs to make sure all are operating as expected. 4. Select one and discuss. For example, the Energy per Cookie Weight value. It is 0.19 kw/kg, which is well within spec. The Director of Operations gets back from an early lunch at 12:30pm and grabs a coffee. At 1pm she has a staff meeting with her VP, but wants to get up to speed on how the sites are doing. She opens her Microsoft Surface and launches her KPI tool to see if there are any current issues that she may need to bring up during the staff call. She checks a number of her key KPIs and quickly scans the list to see if any items stand-out. She likes to see that the Energy per Cookie Weight is at 0.19, the team have really made a noticeable improvement in this area and she reminds herself to send them an to congratulate them. This screen offers a great way to visually review many KPIs at one time. The display is role-specific. Tightly integrated with Windows interface. Allows drill-through to determine greater detail. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 8 of 36

10 2. Page Description This is the KPI map view. This view shows the selected KPIs (and their relevant information) at each of the MightyQ s locations. The color of each KPI reflects their state. 1. Right click the top banner of the KPI application and select the Map KPIs icon in the bottom right to open the map page. 2. Place your cursor near the Brussels facility and zoom in to review the energy demand. 3. Close the KPI app. She opens the map view to see her KPIs, she loves this view as it reminds her that these sites are diversely different and allows her to separate KPIs per region. All looks good. She zooms into Brussels as she thinks about the KPIs. Highly-useful KPI view for geographically diverse organizations. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 9 of 36

11 Chapter 2 Analysis across Sites Mobile 1. Page Description The FactoryTalk VantagePoint mobile site is used to navigate to and display the Corporate Overview dashboard. This dashboard shows the current Shift OEE, current Energy Demand, and Energy Consumption over time for all three sites. This provides a quick overview as to how the sites are performing. 1. Log into the VantagePoint mobile site in a browser. 2. Click Model. 3. Click MightyQ s Enterprise. 4. Click Analytics. 5. Click Corporate Overview from the display navigation across the bottom of the display to generate the Corporate Overview report. The Director of Operations realizes she will be late unless she gets going, she closes her Microsoft Surface and heads to the conference room. She arrives at the meeting with a few minutes to spare and opens her Surface. Not having completed her initial Energy analysis she opens her browser and goes to her Mobile site. It was only a year ago that they started the project to provide more information to Plant Staff and Operations she can t believe how they ran Operations before they had this information at their fingertips. She selects the Corporate Overview and maximizes the dashboard to be able to see all the details. Although the meeting has started she continues to multi task having this information available to her and her staff at any time as changed the dynamics of these meetings. They are now using the information to make decisions faster with more accuracy. This report shows her a quick overview of the three sites. Believe it or not this is a dashboard she developed. The plant staff along with their Systems Integrators prepared a system that allowed her to find information easily and present it in a format she wants. There are many reports that others have created, but the ability to provide self BI help has been invaluable. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 10 of 36

12 She checks Energy Demand and reviews the OEE parameters. She is concerned that OEE is lower than it should be and she better make a point of getting together with her Plant managers to see how she can improve these numbers before the VP sees this which could be soon as he has access to the same information. It appears that, at least at a high level, the issue is due to Throughput (are we running our lines below spec?). She notes that Chicago has a lower Energy Demand than Brussels; interesting as these two plants are essentially identical having bought the lines from the same vendor. It is her time to present her status at the Staff meeting so she stops multi-tasking for the moment; returning to her analysis as soon as she is done. The mobile display is rendered using HTML5 making it available on all devices. Users can easily develop their own reports using pre-built widgets. Dashboards are templatized, such that they can be re-used by others and applied to similar systems. The user can develop dashboards by leveraging the UPM (Unified Production Model), which can access and combine data from one or more data sources such as individual machines on the line or the entire plant floor. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 11 of 36

13 2. Page Description The Site Comparison Score Card provides details on various Plant attributes for all three facilities over the last 12 months. It is an Excel report rendered in the Mobile site. The best-performing site in each category is indicated by a green highlight. 1. Click Site Comparison Scorecard to open an Excel-based site comparison report. 2. Review the information. She next navigates to the Site Comparison report to compare her KPIs over the last 12 months. This was one of the reports that the team built about 3 months ago. It was a real collaboration between IT and OT Teams; a rare occurrence yet another example how she feels the IT and OT folks need to work closer together. This report highlights which Site is performing best in each of the areas of interest defined by her VP. It seems that Chicago is performing the best with respect to Energy Demand and consumption (which lines up with her earlier observation), but it is slightly behind on Energy Intensity with respect to Brussels; which is odd as these are essentially sister plants. Why is it different? Why is Energy Intensity (a measure of how well you utilize 1 kwh of Energy to create 1 kg of product) different between the 2 sites. This requires further investigation. The meeting ends quickly and she heads back to her desk to finish her analysis before her next meeting. The report provides a balanced scorecard for KPIs across the organization for senior leadership to review. This report could have easily been defined to display a different duration, such as the last 30-days. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 12 of 36

14 Chapter 3 Analysis across all Sites - Trend 1. Page Description Using the FactoryTalk VantagePoint Trend tool, this ad-hoc trend report shows a comparison of the energy demand over the last 12- hours for the three different sites. 1. Open VantagePoint Trend. 2. Navigate the model and add the Energy Demand property for each site. You can simply double-click the property to add it to the trend. 3. Change the time period to cover the last 12 hours. 4. Using the toll bar, turn on the vertical cursors and stack the trends for better comparison. 5. Slide the vertical cursors over the trend to review the values for each site. Demonstrate that Chicago is running at the lowest Energy Demand and Singapore at the highest. The Director of Operations grabs a fresh cup of coffee and opens Trend - she wants to look at more history to see if anything catches her attention. Is this a blip in time or is this something that has been happening before. She first wants to confirm what she saw on the Mobile site where Chicago was running at a lower Energy Demand then Brussels. She navigates the model and adds the Energy Demand property from each Site. The fact that she does not need to know where this data comes from nor how to get it is a real bonus. She knows that the system is secure and that she and others can easily get to the information they need without having to have IT create a custom report for her. Adding each site s Energy Demand, she changes the time to cover the last 24 hours in order to see some recent history, adds the vertical cursors and stacks the trends. Moving the vertical cursors around, it is clear that Chicago is running at the lowest Energy Demand and Singapore at the highest (most 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 13 of 36

15 likely due to Singapore also having the highest output). The spikes she sees is probably a result of shift changes but she will check with the plant on the next call. But this still does not explain the low Energy Intensity in Chicago. 2. Page Description The UPM allows the User to easily find information. The Trend application supports Ad-Hoc or Self-Help analysis, enabling users to search and find data relevant to their needs. The data may come from disparate systems, but the UPM abstracts the User from having to understand the nuances from the various control and information systems. Supports quicker time to resolution no need to get others involved. This trend reports shows the following: Hourly Consumption (kwh). This value is a calculation from the Historian that is performed hourly. It allows users to compare hour to hour how much Energy, in kwh, is consumed. Energy Demand (kw). This is the rate at which energy is being used. Energy Intensity (kwh/pallet). For the Line, this is a measure of the Energy used per Pallet. It is becoming more common place for manufacturers to concern themselves not only about physical consumption, but also intangibles like Energy, Water and Steam used in the manufacturing process, as these can have a considerable impact on overall cost. 1. Using the UPM, navigate to the Reports folder under the Chicago Plant. 2. Open the trend called Line 1 Energy Overview (8hr). 3. Move the vertical cursors over the data to review the details. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 14 of 36

16 4. Identify any anomalies like spikes in Energy Intensity (the goal is to keep Energy Intensity low and flat). The Director of Operations opens a report that the Black Belt team created last month when they were looking at Energy consumption in Chicago; Line 1 - Energy Overview (8hr). She notes that the Energy Demand looks fairly normal, except the slight dip which must have happened over the last hour or so. Energy Intensity looks fairly flat until the last hour where it jumps. She has one more report that she will review to see if she can determine what is going on. 3. Page Description The application allows the user to examine the data in an ad hoc fashion. This report was developed by others, but made available to all. Calculations that combine data from various data sources can now be performed allowing for ever more complex and strategic KPIs. This trend report shows Energy Intensity (blue line) compared to Target (red line) and identifies instances where Energy Intensity breaches the set targets (shaded regions). 1. Open the trend called Line 1 Energy Intensity to Target (24hr) trend. 2. Identify the times when EI has exceeded the target. These instances are highlighted making it easier to identify. This trend compares the calculated Energy Intensity to the target rate that was defined by the Black Belt team. In a past role, one of her responsibilities was to create a report just like this; she remembers how challenging it was to get the data from the various systems in 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 15 of 36

17 order to do this. Now she just clicks a button and bam it is there. I love Technology. Looking at the trend she sees that over the last 24hrs Energy Intensity has breached the limit 3 times (she really needs to ask someone to configure the system to send her an when this happens next time she knows this is possible). The red highlighted area makes this stand out quite clearly. What s going on? She has no time to dig into this deeper and decides to call the Maintenance Manager in Chicago to see if he can help. 1. Boolean conditions can be highlighted on a trend making it more visible to see certain conditions. 2. The eventing engine can be used to notify Users of various conditions, increasing awareness and reducing potential downtime or unfavorable production situations. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 16 of 36

18 Chapter 4 Equipment Performance - Mobile 1. Page Description The Mixer Overview is a VantagePoint mobile dashboards that illustrates the various process and performance variables for the machine. The mobile trend illustrates the level within the silos that feed the Mixer. 1. Open a browser and point to the site. If you use Internet Explorer you will need to select the VantagePoint Mobile menu item from the Tools menu. 2. Select Model and navigate to Chicago Line Select Assets then Mixer. 4. Select the Mixer Overview dashboard. 5. Maximize the display. 6. Review the dashboard then click the Silo Levels dashboard to view the report showing available amounts of materials. The Director of Operations in Brussels has called the Maintenance Manager in Chicago let him know that she suspects that the Line is running above its target Energy Intensity. She asks him to review the situation and get back to her once he understands the situation. The Maintenance Manager happens to be standing next to the Mixer with his tablet. He knows that between the Mixer and the Oven they consume the lion s share of the Energy on the Line and decides to take a peek at how it is running. He goes to his Favorite list and selects the Mixer Overview dashboard and maximizes the display he knows this is the fastest way for him to get to the Mixer area. This was one of the reports that the SIs developed based on his input, the idea that one report template can be used for all of his machines still impresses him. He remembers his Engineering days when he would have had to create a report for each machine it would have taken weeks if not days. He scans the report looking for anomalies. He can smell the Oat Meal in the air and confirms that the Product ID is OAT MEAL. Energy Demand is within limits, actually it is running great, and Energy per Batch is also low; his gut feel is that the Mixer is not the 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 17 of 36

19 cause at least not today. His only concern is with OEE, it is low and getting close to the red line (not what he wants to see nor will the Plant Manager). Availability and Quality are very good, throughput is low this must be the issue. This could also explain a low Energy Intensity as they are not putting enough dough in the mixer to make enough cookies. He will have to get back to that. While at the mixer he checks out the Silo levels to make sure they have enough material to cover the next few Batches. All looks good. Some are running low but he knows they have an order coming in tomorrow. Mobile availability means a User can access information simply using a web browser on their mobile devices from anywhere in their facility. Mixer overview provides details of current operational status. Being able to analyze data from anywhere increases a Users ability to make informed and timely decisions. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 18 of 36

20 Chapter 5 Equipment Performance Desktop 1. Page Description The Line and Machine Overview dashboard, part of the VantagePoint Portal, provides a high level overview of all of the equipment on the Line. 1. Open Internet Explorer and navigate to the Portal. 2. From the Reports menu item select Chicago Site Analytics. This will open to the Line and Machine Overview dashboard. 3. Review the data, pointing out the different products and Batch IDs currently in the line. In the example here, some of the equipment is working on chocolate cookies, while other equipment is being used for oatmeal. All equipment status is green except for the mixer and oven. He walks back to his desk pondering what could be wrong. Putting his tablet down, he moves to his desktop and unlocks his machine. He leaves the Line and Machine Overview open all the time so that he can keep an eye on his Line. Although he has notifications setup to alert him on issues, he can t get away from seeing this overview. This view allows the Maintenance Manager to keep an eye on his line at all times to quickly and easily determine the state of the line whenever he or she needs to. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 19 of 36

21 2. Page Description The Top Alarms by Duration report shows the alarms from the last hour. The user can change the time frame, but in this case the top alarm has the longest duration and merits a closer look. Continuing to drill into the top alarm allows the user to compare the Alarm with process variables. 1. Collapse the Chicago > Areas leaf in the left pane. 2. Expand the Chicago > Reports leaf in the left pane. 3. Expand the Mfg Operations leaf in the left pane. 4. Navigate to the Top Alarms-Duration report under the Analytics folder to view the Alarms for the last hour. 5. Click on the top alarm to view it in more detail. Wondering if the Energy Intensity issue could be related to low throughput, he wonders if they have had any alarms that may be contributing to this result. He navigates to the Top Alarms Duration report. He and his team have been able to organize their reports into the folder called Mfg Operations Analytics, it makes it very easy to find reports quickly. This report shows the Alarms for the last hour he can change the duration but instead decides to drill into the top Alarm; as this has the longest duration. This provides more detail about the Alarm. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 20 of 36 The reports used by the Maintenance Manager s team are organized into the folder called Mfg Operations Analytics, which makes it very easy for them to find reports quickly. The system is integrated with device-based FTAE (FactoryTalk Alarms and Events) to provide crucial information on any alarms that have been triggered in the system even for people who do not have access to the View SE HMI screens. This keeps all

22 3. Page Description alarm configuration and the processing of those alarms and events in the controller. The Alarm Analysis Report identifies when an alarm was high and then overlays selected variables on the trend allowing a user to analyze Process Variables and Alarms synchronized in time. This is a SQL Server Reporting Server (SSRS) report hosted within the VantagePoint portal. 1. Click on the Alarm one more time to open the Alarm Analysis Report. 2. Review the report content. He continues to drill in as he wants to be able to compare the Alarm with process variables. He clicks on the Alarm one more time to open the Alarm Analysis Report. This is one of the new reports that was recently added to the system. The ability to combine process variables, which can be configured, with Alarm information has helped him identify a number of issues in the plant. It may help today. Although still interested in trying to resolve the issue at hand, the current Alarm has him distracted and he wants to get this addressed immediately. He heads to the Control Room to ask the Line Operator if he is taking any action on this alarm. The ability to combine process variables, which can be configured, with Alarm information has helped identify a number of issues in the plant. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 21 of 36

23 Chapter 6a How s the Line Running? (ViewPoint) 1. Page Description This published FactoryTalk ViewPoint Overview screen for the Line shows individual line components and current status information for each machine. This display was designed and optimized for mobile platforms. 1. Open a web browser and navigate to the ViewPoint Mobile site. 2. Navigate to the m_overview display. 3. Review the relevant information to verify that the line is running as expected. The Maintenance Manager leaves his office and heads towards the Control Room. He sees the Operator working on a report and asks if he is aware of the Alarm he is. He explains how the Director of Operations had called him asking about the Energy Intensity anomaly and he got a little side-tracked into looking at this issue. He asks how the Line is running hoping it may provide some insight. The Operator goes on to explain the key areas that he tends to look at when anyone asks him this open ended question he has been doing this for many years and knows all the ins and outs of this factory. He moves over to his primary display and opens a Line Overview screen via a web browser. I typically check that the system is running and that the Oven is at temperature. Securely extend the view and control of your process onto a mobile platform for improved access to information. There is no client software to install or maintain, lowering total cost of ownership. Access to critical information is simply done from a web browser. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 22 of 36

24 Tight integration to the Logix control platform provides critical visibility into the process for the Line Operator. 2. Page Description The Mixer display shows what product the line is making, the Batch ID and the current step the machine is in. 1. Navigate to the m_mixer display via the breadcrumb navigation in order to view the Mixer s current status. 2. Review the relevant information. 3. Navigate to the m_oven display via the breadcrumb navigation in order to view the Mixer s current status. 4. Review the relevant information. The Operator continues I then go to the Mixer display to check on what product we are actually making and check that the Energy Consumption is within spec. The Mixer is the critical piece of the line, so it is important that it is running well. In this case, the Energy Consumption looks normal. The Operator continues once again I also need to check the energy consumption and temperatures on the Oven. All looks good. The Mixer and the Oven are the two largest energy consumers, if there is a concern with Energy Intensity, this is a good place to start. These displays provide a view of both real-time and historical data for critical machines in the process. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 23 of 36

25 3. Page Description The System display shows server and diagnostic information. This page can be used for System Health Monitoring as well as troubleshooting issues as it may identify suspect sub-systems. Navigate to the m_ System display via the breadcrumb navigation to view the system display. Review the relevant information. The Operator continues, The last check I do is go to the System display. I know the Controls and IT guys use this display a lot from the Control Room or mobile device. As long as nothing looks out of the ordinary, I am happy. Provides a quick visual status of the Control System. Provides data from many sources in one location - IT information for the host servers as well as system diagnostics for key servers in the system. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 24 of 36

26 Chapter 6b How s the Line Running? (ViewSE) 1. Page Description This FactoryTalk View SE Overview screen for the Line shows individual line components and current status information for each machine. 1. Double click the MightyQ.cli file from the desktop to open the FactoryTalk View SE client for the MightyQ s Line. 2. Review the relevant information to verify that the line is running as expected and tank levels are acceptable. The Maintenance Manager leaves his office and heads towards the Control Room. He sees the Operator working on a report and asks if he is aware of the Alarm he is. He explains how the Director of Operations had called him asking about the Energy Intensity anomaly and he got a little side-tracked into looking at this issue. He asks how the Line is running hoping it may provide some insight. The Operator goes on to explain the key areas that he tends to look at when anyone asks him this open ended question he has been doing this for many years and knows all the ins and outs of this factory. He moves over to his primary display and opens the Overview screen. I typically check that the system is running. The Oven is at temperature and we have our key ingredients in our silos. Tight integration to the Logix control platform provides critical visibility into the process for the Line Operator 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 25 of 36

27 3. Page Description The Mixer display shows what product the line is making and the ingredients used in the current Batch. 1. From the top navigation click Mixer to view the Mixer s current status. 2. Review the relevant information. The Operator continues I then go to the Mixer display to check on what product we are actually making and that the ingredients are listed correctly. If the Energy Consumption is within spec and the motor history looks correct I move on to the Dashboard Display. The Mixer is the critical piece of the line, so it is important that it is running well. In this case: The ingredients look accurate and in line. The Motor Speed and Energy Consumption look good. The Mixer and the Oven are the two largest energy consumers, so if there is a concern with Energy Intensity, this is a good place to start. This screen provides detailed real-time and historical data for one machine on the line, in this case the Mixer, which is the critical machine in the process. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 26 of 36

28 4. Page Description The Dashboard display provides production information for each machine on the Line. In addition, it displays critical KPIs and current Alarms. 1. From the top navigation click Dashboard. 2. Review the relevant information. The Operator goes on to say, The Dashboard display is great for a quick overview to see what is going on. I like the fact that I can see more than just what is happening within the control system but what is also being displayed to our Management; having access to this information allows me to be more cognizant of the issues we are trying to address at the Plant level and even corporately. 5. Page Description Combining reports and analysis with production data provides the Operator and Maintenance Manager with many layers of information in order to make better decisions. The System display shows server and diagnostic information. This page can be used for System Health Monitoring as well as troubleshooting issues as it may identify suspect sub-systems. 1. Click System to view the system display. 2. Review the relevant information. The Operator continues, The last check I do is go to the System display. I know the Controls and IT guys use this display a lot from the Control Room or mobile device. As long as all of my systems are green I am happy. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 27 of 36

29 Provides a quick visual status of the Control System. Provides data from many sources in one location - IT information for the host servers as well as system diagnostics for key servers in the system. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 28 of 36

30 Chapter 7 Descriptive Analytics 1. Page Description The White Board report is a SQL Server Reporting Services (SSRS) report developed using Report Expert and using data from FactoryTalk Metrics; it is hosted within VantagePoint. It displays an hourly overview of how the Line is running and if there are any issues since the start of the shift. The trend at the top shows production values for each hour and illustrates what product was made in that hour. The chart at the bottom provides a tabular view of the same data in the chart with greater detail. It also includes the OEE values for each hour. 1. Open Internet Explorer and navigate to the Portal. 2. From the Roles Menu, select Mfg Operations to display the default White Board report. 3. Review the information shown on the report. The Operator continues to discuss what could be causing the Energy Intensity issue with the Maintenance Manager when the Plant Manager walks by and asks this looks serious, what are you two up to?. He gets the background to the story and asks that they both keep an eye on the situation. The Plant Manager heads back to his desk; he is now concerned that the Director of Operations has seen something and wants to try and get ahead of this issue. He pulls up his chair and sets up in front of his work station. He has been driving for more information in this plant for years and is happy that he has finally the information he needs to make better, and faster decisions to meet his responsibilities. He wants to impress his management with his knowledge of the system and his ability to analyze the data. He opens the portal, logs in, and navigates to the Mfg Operations role page. The default report, White Board, is the report he keeps open on his desk. It shows him an hourly overview of how the Line is running and if he has issues. Being able to separate what cookies were being made during the last few hours is critical as in the past some of the 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 29 of 36

31 challenges have been with supplier ingredients; which is only noticeable when making Oat Meal cookies. Being able to separate what cookies were being made during the last few hours is critical in isolating the issue. The information displayed on this report is a common request from Shift Supervisors and Plant Managers. It visualizes the performance of the Line during the current Shift. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 30 of 36

32 2. Page Description At a high level the kwh_db report provides details about the Total Parts (or cookies) produced and the kwh consumed to make them over a given duration. It identifies total production in hourly buckets (as a bar) and aligns them across time (showing the total amount of time in the top right hand corner). It then overlays the Energy (kwh) used to produce the cookies (blue line). This information is available for each formulation and for each piece of equipment on the Line, including the Line itself. Items that are underlined can be selected in order to change the view and filter the content. 1. Navigate to the kwh_db report in the Mfg Operations > Analytics folder in the left pane. 2. Review the information shown on the report. He doesn t dwell on the White Board report as his focus is on Energy, he opens the kwh_db report in order to start to investigate the Energy Intensity issue. This dashboard allows him to compare Throughput and Energy Intensity across the Site, Line and Formulation; it is his go to report with respect to any Deep Dive analysis. He selects the parameters he is after, and minimizes the parameter selection options section. At a high level the report provides details about the Total Parts (or cookies) produced and the kwh consumed to make them over a given duration. It identifies each Mix that was run (as a bar) and aligns them across time (showing the total amount of time in the top right hand corner). It then overlays the Energy used to produce the Mix (blue line). This is available for each formulation and for each piece of equipment on the Line, including the Line itself. He scans the report looking for obvious patterns where the Energy consumed does not line-up with the number of cookies produced; he doesn t see any outliers. He clicks on one of the green bars to drill into the next layer of analysis. 1. The kwh_db report is a pre-built report. The report is flexible, and the user can change context to view what is needed. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 31 of 36

33 2. Enables the User to filter the data by various context, including formula and equipment. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 32 of 36

34 3. Page Description This page provides visual representations of ways to slice the data: by formulation, shift, operator, and part counts. It allows you to drill into specific data for greater detail, such as by formulation in this example. 1. From the kwh_db report click on one of the green bars to drill into the data. 2. Look for potential causes of low Energy Intensity. 3. Click on the Oat Meal bar under kwh by Formulation to filter the chart for the Oat Meal formulation. He now has a dashboard that provides visual representations of different ways to slice the data. He has found that you cannot always rely on one way to look at data, sometimes you need to view it from different perspectives to uncover the information within. As the kwh by Formulation and the Energy Intensity by Formulation charts both appear to be fairly flat, as he would expect, it is the Avg Max kwh by Formulation bar chart that attracts his attention. Each bar represents the average energy used on the left and the maximum energy used on the right. The width of the bar represents the diversity in energy used to create different batches of the same formulation. Ginger cookies looks about normal, whereas both Butter and Oatmeal have very high maximum energy values this is concerning. He decides to drill into the Oatmeal cookies a little deeper to see if anything catches his eye. He clicks on the oatmeal bar in the top left chart. The report is now filtered by the Oatmeal formulation. The Energy Intensity Total Parts by Hour graph catches is attention. He notices that while Energy Intensity remained relatively flat, the cookie production was dropping. This lines up with what the others had seen with respect to low throughput on the OEE reports. Even though Energy Intensity was remaining close to the Brussels plant, his 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 33 of 36

35 output was dropping. He thinks of a new KPI that would help identify this issue, like Energy Intensity at standard operating conditions ; ie Energy Intensity should take into account that we were running at lower through-put. He will have to suggest this to the Director of Operations. He is pretty happy that he has confirmed what management is seeing and understands how it is happening, now he needs to figure out why it is happening. He will have to bring this up at his staff meeting tomorrow. He sends the Director of Operations a quick and forwards her the link to the report so she can check it out for herself; he is done for the day. The page provides analysis by context. Context is all about combining data together to gain more insight. For example, it s not just about the energy used, it s about the energy used while producing a specific formulation of cookies on a specific line. Great tool for looking at more general or more specific data in different ways. 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 34 of 36

36 Summary Some of the key messages from the script are as follows: Various products and services were integrated to develop this solution in order to provide the analysis demonstrated Providing access to contextual and timely information at each and every level in an organization is critical to a successful Connected Enterprise With information at their finger-tips, Users are able to solve issues faster and more collaboratively Users were able to access information from the desktops, from tablets and mobile devices 7/5/2016 Rockwell Connected Enterprise Rev 1.00 Page 35 of 36